Method and apparatus for casting journal boxes



Aug. 4, 1931. w..MELcHER 1,317,388

METHOD AND APPARATUS FOR CASTING JOURNAL BOXES Filed Feb. 16. 1929Patented Aug. 4, 1931 i UNITED sTAfrEs;

PATENT ori-ics LEE W. MELClHER, F DE PERE, WISCONSIN, ASSIGNOR-*TO FFNIBBEARING COIPAN'Y, 0F NEW BRITAIN, CONNECTICUT, A CORPORATION OFCONNECTICUT. f

nn'rnon im Armures ron cas'rme JOURNAL ,noxes- Applcation filed February18, 19,89.' Serial No. 840,417.

The invention relates to casting journal boxes for roller-bearings. Inthese boxes it isadvantageous vto forman integral cylindrical wallhaving -a bearing surface for the rollers to avoid the ne'essity of aseparate hard metal bearing sleeve. It is also advantageous to form. theupper ortion or load zone ofthe integral wall o hard metal in order toresist wear.

4 character, it is necessary that the load zone of hard metal in thecylindrical 'wallsh'ould be of suicient thickness to form a structurewhich will be reliably resistant to wear for 16 a long period of time,after it has been v ground or finished. One object of the prese'ntinvention is to provide an improved method of producing journal boxes inwhich the load zone of the cylindrical wall will be 20 hardened and ofsuilicient depth to withstand efiiciently wear.

Another object of the invention is to provide an improved method ofproducing journal boxes of this character, in which the impurities inthe molten metal are-kept awayfrom that portion ofthe cylindrical wallin which the load zone is formed and are caused to accumulate in aportion of the box which is notused as a(bearing surface.

A further object of the invention is to provide an improved method ofcasting journal boxes in which the sides and top of the journal box, aswell as the pedestal guides and equalizer seats are formed of hardmetal.

A still further object of the invention is to provide a?) improved moldfor use in casting journal oxes having an integral cylindrlcal bearingwall.

Other objects of the invention vwill be apparent from a considerationofthe following detailed description.

The invention consists in the several novel features hereinafter setforth and more par! ticularly defined by claims at the conclusionhereof. y f 'f A.

In the drawings Awhich accompany and form a partei this specification ordisclosure and in which like numerals of reference de-y notecorresponding parts throughout the several'views; Fig. 1 is a section ofa mould In journal boxes of the aforementioned.

showing the preferredy manner of carrying outl the invention. Fig. 2 isa section 'taken' on the line; 2--2 of Fig. 1. Fi 3 is a section of thejournall box produced y the present method and in the improved mould.

v The invention is exemplified in assembling certain cores in a flaskwhich` comprises a cope 4 and a drag v5. The flask is first placed von abottom-board 6. A bed 7 of sand is then packed on said board. A dry-sandcore 8,

which has its top face shaped to form thel bottom a of the journal boxais then placed upon the sandbedv?. Chill-sections 12, with dry-sandcores 13 baked on the outer sides thereof, are laid on the bottom-core8. These sections 12 are shaped and spaced apart to cause a layer a2 ofhard metal at the side-` faces a of the box a, and are provided withvertical grooves 14 in their inner faces, to form hard-metal pedestalguides'as on the sides of the box. Dry-sand cores 9, which are sha a,are p ated on the bottom-core 8 and across the ends of thechill-sections 12 and cores 13.

A cylindricalA opening a". is formed in the box to provide an integral'correspondingly cylindrical bearing-Wall ai.' or race 1n the box a, fora series of rollers around an axle in the box. This wall a1 is formed bya composite core whichis held in prints in and extending across thespace between the end-cores 9. This composite core consists of achill-section 18 and a dry-sand section 19 which are baked together andhave their peripheral portions shaped to form the cylindrical opening ain the casting. The periphery 18s of chillsection 18 extends throughoutless than 180,

preferably about 160, of opening a, to form ahard-metal zone a ofcorresponding area which constitutes the load zone of the bearing walla. Dry-sand section 19 forms the remainder of the wall a' of soft metal.The bottom face of chill-section 18 is recessed, and sand section 19extends into the recess, so the two sections will remain corelativelypositioned to form truly the opening a. The composite core is'positioned so the axis of opening a will be horizontal and thechillsection 18 is placed at the tog, for the purpose hereinafterdescribed. rysand cores d to form the end-walls of the box 2O are heldin core-prints in end-cores 9 and extend longitudinally across the spacearound a hard metal face, a on the top 'of the box a, i

and has a recess 15 to form a Yhard-metal equalizer seat a on the to ofthe box, and cross-grooves 15l to form ard metal guideribs alz for theequalizer bar, at the ends of seat a. After the parts of the mold havebeen assembled in the flask, the s ace 7 beimv ` a comparative tween'thewalls of the fiask an the sidecores 13 and end-cores 9, is filled with-sand so that the mold will be surrounded by sand to permit expansion ofthe parts of the mold. A vertical 4gate 23 extends downwardly f throughtop-core 15'* and one of the side cores 13 to a horizontal te 24 4invbottomcore 8 below chill 12. e gate 24 is connected by a' restrictedupwardly extending gate to the space which is to be filledwxt metal.vOne or more gas vents (not shown) extend through the chill 15 and core15".

In practice it has been found that if the l metal is permitted toA boilor to be excessively a 'tated dur the rocess of urin only g1 mf thiiifilm of xliiztal vgvill be hardened by t e chill-sections so that'thehardened zone will not be effective to revent wear particularly on thecylindrical ring surface. It has also been found that when thetemperature of the various chill-sections is too low, the metal willboil or agitated excessively and displace the previously derenheit atthe commencement of the I agitation which results from the positedportions on the chill-section, andto minimize this, thechill-sectionsare heated a roximately to 180 Fahrenheit. The c ills areheated to somewhat higher teinperature before they are placed in themold, and the period of pouring with respect to the closing ofthe mouldsis timed the temperature of approximately180 Fah- .umg operation. Allrts ofthe moul which form soft metall-m portions of the box are formedof dry-sand cores, to minimize the production by\mol'sture in the mould.en the mould has beenp'repared as set forth, the molten metalatapproximately 2500 Fahrenheit is poured into the gate 23, fromV which itflows through the gate 24 and then upwardly through the restricted gate25 into the bottom ofthe space in which the box is formed. In pouring, aconstant supply of molten metal is maintained in the down-gate by reasonof the restriction'in the edge ofthe chill-.section '18, itprogressively flows over the eripheral faceof the chillsection 18,v and)the subsequently incoming metal will riseadjacent the side chillswithout displacing th'e metal which has been previously deposited on theperiphe of chill-section 18. In practice it has en found that any flowof the molten metal over reviously deposited metal on a chill will avethe effect of reducing the thickness of the hardened zone. ,x As aresult, the zone of metalhardened by the chill 18 will be of suiiicientthickness, for examplee 1% of an inch', to form an effective hard metalbearing surface in the load zone in, and integral with, the cylindricalbearing wall. The impurities in the metal, by reason of avoidingexcessive agitation, will remain on the top of the flux and accumulateat the top of the a5 box and will not be deposited ,on the loadl zone ofthe cylindrical wall. This is iinportant, because the presence ofimpurities in 'the load zone is objectionable, while their presence' isnot objectionable in 100 the top of the box which is not used'as abearing surface. During this pouring,

the metal flows upwardly between. the4 constricted .portions of thespaces at the sides of the core 19 and the chill 12, and, as 105 aresult, the zone of hard metal at the central side portions of the boxmay be somewhat irregular in de th or narrower than the hard metal inthe oad zone of the cylindrical wall. This however is of no moment, nobecause such portions of the box are not subjected to great wear. Thepouring of the metal is continuedy until the'entire space in the mouldhas been filled. Chill-section 15 forms a hard metal portion on whichthe 115' equalizer seat is formed so that it will resist wear. The'chill-sections 12 harden the metal in the sides of the box and in thepcd-- estal guides to render them wear-resisting.

' In cooling, the expansion of the metal will 12o contract the openin aand force the chillsection 18 downwar 1y and toward the cen-A ter of thecylindrical wall and will crush the sand-core 19. This eliminates shrinkcracks z and distortion of the cylindrical wall of the box which wouldotherwise result from .the

.expansion of the metal and contraction of the 'cylindrical wall, andalso facilitates the Aremoval of the chill.

The invention Yexemplifies a method of 131* which consists in preparinga mould with a' casting journal boxes with an integralcylin- .d riealvwall for a bearing surface with a hardened portion in the load zone ofsufficient thickness to be effective and to rmit the necessary finishingor grind' t also exemplifiesa casting method l:vich roduces a load zoneof hard metal in the cy indrical Wall of uniform thickness andcomparatively free from defects caused b impurities in the metal. `Italso exempli es an improved method by which uniform castings will beproduced at a low cost.

The inventionpis not tol be understood as restricted to the details 'setforth, -since these may be modified within the sco of the a pendedclaims, without` departing from t e spirit and scope .of the invention.

' I claim as new and desire'to secure by Letters Patent, is:

`1. The method of casting a journal box having an integral cylindricalbearing wall, which consists 1n reparing a mould with a chill sectionsha e to form a hard metal load zone in said cy indrical wall andarranged so that its periphery faces upwardly and extends horizontalland with a core to form the remainder o the cylindrical wall, andpouring metaly from below into the cavity around the core and chillsection so it will flow upwardly and progressively over the peri heryofthe section-to form the hardene load zone without displacing anysubstantial portion of the metal previously deposited on thechill-section.

2. The method `of casting a journal'box having an' integral cylindricalbearing wall,

chill-section shaped to form a hard metal load zone of less than 180 insaid cylindrical' wall, arranged so that its peri hery faces upwardlyand extends horizontall) and with a core to form the remainder o 4thecylin drical wall, and pouring mtal vfrom below into the cavity aroundvthe core and'chill member so it will flow upwardly and progressivelyover the periphery of the section to'form the load zone Withoutdisplacing any substantial portion of the metal previously deposited onthe chill-section and cause said zone to be comparatively thick.

3. The method of casting a journal box having an integral cylindricalbearing wall,

- load zone in said cylindrical wall and arthe periphery of the sectlonand form the load zone without displacing any substanshape tial tportionof the metal previously deposited on e tluck chill-section so that it iscomparativeiy d to formthe remainder of the cylin-, drical wall of softmetal'and adapted to permit the ,chill-section to be forced toward thecenter of the opening by the expansion of the metal, and pouring metalfrom below into the space around the core and chill-section, so it willprogressively flo w over the periphery of the chill-section withoutdisplacement.

5. The method of casting a kjournal box having an internal cylindricalbearing wall, which consists in preparing a mould with chill-sectionsshaped to form the sides of the box, a chill-section shaped to form azone of hard metal of less than 180 in the cylindrical wall with itseriphery facing upwardly, a sand core to of the box, a cylindricalchill-sectionshaped f toy form a zone of hard metal of less than 180 inthe cylindrical wall, a dry sand core to form the remainder of thecylindrical wall and a dry sand core to form the bottom of the box ofsoft metal, and pouring metal from below into the cavity around thefirst mentioned core and between the chill-sections.

7. The 'method of casting a journal boxl having an integral cylindricalbearing wall, which consists in preparing a mould Awith chill-sectionsto form the sides and top of the box, a cylindrical chill-section shapedtoA form` a zone of hard metal in the cylindrical wall, and a dry-sandfilling to form the bottom of the box of soft metal, and with cores toform bolt holes extending through the box, and pouring metal from belowinto the cavity around the core and between the chillsections.

8. The method of casting a journal box having an integral cylindricalbearin wall, which consists in preparing a moul orm the remainder ofthe\ cylindrical wall, and pouring metal from f ics with l chillsections to form the sides, a chill-section to form the top of the boxhaving a. recess therein to form an equalizer seat of hard metal, achill section shaped to vforma zone of hard metal in the cylindricalwall, asand l core to form' the remainder ofthe cylindri- 50 j arrangedwith the chill-section on the top -zone of hard metal in the cylindricalwall, and

means forming a gate leading upwardly to the space below the core.

10. A ymould for a journal box having an integral cylindrical bearingwall, comprising a flask, a chill section and a sand section unitedtogether to form a composite core and arranged with the chill-section ontop and in the mold cavit so as to form the cylindrical bearing wall orthe box with a. hard metal upper zone, chill sections shaped to formvthe sides and top of the box, a dry sand core to form the bottom of thebox, and'means in the flask forming a gate leading upwardly to the spacebelow the core. l y

11. A mould for a journal box having an integral cylindrical bearingwall, comprising a flask, a chill-section and a sand section unitedtogether to form a composite core and arranged with the chill-section onthe top and in the mould cavity so as to form the 'cylindrical bearingwallfor the box with a' hard metal upper zone, chill sections shaped toform the sides of the box, a chill section shaped to form the top of thebox, having a recess to form an equalizer; seat of hard metal, and meansin the flask forming a gate leading upwardly to the space below thecore.

12. A mould for a journal box having an integral cylindrical bearingwall, comprising a flask, a chill-section and a sand section unitedtogether to form a composite core and arranged with the chill-section ontop and in the mould cavity so as to form the cylindricalbearing Wallfor the box with a. hard metal upper zone, chill-sections to form thesides of the box, a dry-sand core to form the bottom of the box,dry-sand cores to form the ends of the box, and a gatev in thebottomcore.

'13. A mould for a journal box having an integral cylindrical bearingwall, comprising a flask, a chill-section and a sand section unitedtogether to form a composite core and and in the mould cavity so as toform the cylindrical bearing wall for the box with a hard metal upperzone, chill sections to form the sides/of the box, ay dry-sand core toform the bottom ofthe box, dry-sand cores to form the ends of the box, achill-section to form the top of the box, and a gate in the bottom core.

L4. A mould for a journal box having an integral cylindrical bearingwallcompr1sing1 a flask, a chill-section and a sand section unitedtogether to form a composite core and arranged with the chill-section onthe top and in the mould-cavity so as to form the yday of January, 1929.

cylindrical bearing wall for the box with a hard metal u per zone,chillesections to form the sides of t e box, a dry-sand core to form thebottom of the box, dry-sand cores to form the endsof the box, dry-sandcores backing the side chill sections, and a gate in the bottom core.

15. A mould for a` journal box having an integral cylindrical bearingwall, comprising a flask, a chill-section and a sand section. unitedtogether to form a composite core and of the'box, dry-sand cores toformthe ends of the box, a chill section to form the top of the box,dry-sand cores backing the side top chill sections, and a gatein thebottom core.

16. The combination of claim 14 with a filling of sand under the bottomcbre and around the side and end cores.

1,7. Thercombination of claim 15 with a lling of sand under the bottomcore and around the side and end-cores. q

Signed at De Pere, Wisconsin, this 28th LEE W. MELCHER.

